Hey Guys and Girls,

Let me give ya the lowdown and any help is appreciated!

About 2 weeks ago my bike cut out on my while going about 70+. Power to my powervision, plex audio, headlights, tailights, turn signals, etc were all still functioning. The bike cranked but would not start. Every shop by me is weeks out from being able to take my bike so resorting to some of my own troubleshooting in the meantime. I am no pro!

Over the last two weeks I went through the bike with a mechanic at my garage and checked:
Battery: power, connections, charge: everything checked out and it had more than enough power to start the bike
Wiring: Went through the bike as best as I could (not an electrician) to see if there were any unplugged wires or any that were frayed. Nothing was found here
Engine: Tested compression and tests came out solid so not that
Spark plugs/Wires: Wires look brand new and didnt see anything wrong. Spark plugs have about 3700 miles on them. Swapped plugs just to try and still no spark.
CPS Sensor: put a new CPS sensor in and still no luck
Fuel Pump: Replaced fuel pump as the one in there looked awful, but still no luck

My next thought are the coils and ECU. I ordered a fresh coil to install which should be here in a day or 2, but ECU I know a HD dealership will most likely have to handle.

Has anyone had this issue and what got the bike started again?

Thanks Again

 

Not trying to sound like a jerk but you should invest in a Factory Service Manual.. most likely would save you a lot of time and money..

 

You need to check for codes before buying any more new parts.
Did you load test the battery or just take the voltage at rest?

 

No worries my man, fair comment. I have one and already went through the check list items:1. Fuel tank empty.- I have gas
2. Fuel vacuum line disconnected (if applicable).- solid
3. Discharged battery or loose or broken battery terminal connections.- not an issue
4. Fouled spark plugs.- plugs are in good shape, also used new plugs with correct gap to make sure
5. Spark plug cable connections loose or in bad condition and shorting.- new wires
6. Loose or corroded wire or cable connection(s) at coil or battery.- might be a coil issue but will know by friday
7. Fuel pump inoperative.- new fuel pump
8. Blown fuse.- all fuses are intact.

 

The bike has an aftermarket gauge and today I found out how to check for codes so will be doing that momentarily.

I did both for the battery and both outcomes proves that battery is currently in working condition with proper amount of power according to the service manual and a few blog posts I scrolled through.

 

How do you know you're not getting spark? You need to use an inline spark tester such as this. Need to maintain compression while testing for spark.

 

I'm not really fluent with twin cams and the latest fuel injections on them.. I'm more old school with Evos and Sovels. But my question is do you, @chopper_man can I use a second set of plugs and ground them to the chassis and leave the original plugs in the cylinders to check for spark that way instead of having a spark tester in line? Thanks..

 

I tested it with an inline tester and no spark

 

Ya need to do an OHM Test on the ignition coil.

 

Motor needs compression to spark. If you have a good DVM disconnect the crank sensor, measure the voltage at the crank sensor AC while the cranking. IIRC it should be above 3volts.